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STANDBY GENERATOR SET

1. 29 7 12 PSI 48 83 kPa PRESSURE CAP CZ re 7 T4P 2P AF AP SAE 20R1 OR EQUIVALENT HOSE DOUBLE CLAMPED AT BOTH ENDS WITH DRAIN VALVE AT CONSTANT TORQUE LOWEST POINT FILUMAKEUP HOSE CLAMPS IN SYSTEM LINE THE VENT LINE MUST NOT HAVE ANY DIPS OR TRAPS THAT WILL COLLECT COOLANT AND PREVENT AIR FROM VENTING WHEN THE SYSTEM IS BEING FILLED WITH COOLANT THE FILUMAKEUP LINE MUST BE ROUTED DIRECTLY TO THE LOWEST POINT IN THE PIP ING SYSTEM SO THAT THE SYSTEM CAN BE FILLED FROM THE BOTTOM UP AND NOT TRAP AIR FIGURE 26 REMOTE RADIATOR COOLING DEAERATION TYPE SYSTEM SEE FIGURE 27 Deaeration Type Remote Radiator System A deaeration type of radiator top tank also known as a sealed top tank or auxiliary tank must be provided for 150 kW and larger generator sets In this system a portion of the coolant flow approximately 5 percent is routed to the radiator top tank above the baffle plate where air in the coolant can separate from the coolant before the coolant returns to the system Consider the following e Engine and radiator vent lines must rise without any dips or traps that will collect coolant and prevent air from venting when the system is being filled Rigid steel or high density polystyrene tubing Is recommended for long runs especially If they are horizontal to prevent sagging between supports e fill makeup line should also rise without any dips from the lowest point
2. The fuel lift pump day tank transfer pump or float valve seat should be protected from fuel supply tank debris by a pre filter or sediment bowl with a 100 to 120 mesh element The supply tank must hold enough fuel to run the set for the prescribed number of hours NFPA No 110 Class designation without refueling Tank sizing calculations can be based on the hourly fuel consumption rates on the generator set Specification Sheet Other considerations for tank sizing include the duration of expected power outages vs availability of fuel deliveries and the shelf life of the fuel The shelf life for diesel fuel is 1 1 2 to 2 years For emergency power systems codes might not permit the fuel supply to be used for any other purpose or may specify a draw down level for other equipment that guarantees the fuel supply for emergency power use The Cetane rating of No 2 heating oil is not high enough for dependable starting of diesel engines in cold weather Therefore separate supply tanks for emergency power and building heating systems might have to be provided Approved flexible fuel hose must be used for connections at the engine to take up generator set movement and vibration Diesel fuel lines should be black iron pipe Cast iron and aluminum pipe and fittings must not be used because they are porous and can leak fuel Galvanized fuel lines fittings and tanks should not be used because the galvanized coating is attacked by the sulfuric
3. the preceding footnote Terminal Markings for Various Temperature Ratings and Conductors Load Lead Connections Load leads being brought into the generator can enter in a number of different areas The most common entry point is to stub up below the main line circuit breaker enclosure In some other cases it may be necessary to enter the main line circuit breaker box from the top or side using flexible conduit In either case it is best to contact the factory to get an as built dimensional drawing of your generator set for for more detailed information p a 1 GeneratorJoe Typical Load Lead Connection 55 Terminal Connector Torque with applicable national and local codes when installing a wiring system Use the torque values shown in the chart below for terminal connectors Refer to UL 486A UL 486B Note If a connector has a clamp screw such as a and UL 486E for information on terminal connectors for slotted hexagonal head screw with more than aluminum and or copper conductors See previous chart on one means of tightening test the connector using Electrical Connections for information the both applicable torque values provided temperature rating of customer supplied wire Comply the chart below Tightening Torque Nm in Ib Wire Size for Unit Hexagonal Head External Connection Slot Head 4 7 mm No 10 or Larger Drive Socket Wrench Slot Width lt 1 2 mm 0 047 in
4. C Therefore Heat Rejected Btu Min Raw Water Required gpm set Temp Rise A F x Specific Heat 8 Btu F Gallon rejects 19 200 Btu per minute and the raw water inlet temperature is 80 F allowing a water temperature rise of 60 F 19 200 Raw Water Required ______ 40gpm 60 x 8 Remote Heat Exchanger Remote heat exchanger systems can become very complex taking a variety of configurations especially if a secondary cooling system such as a radiator is used to cool the heat exchanger Most of the considerations above and on the following pages discussing remote radiator systems apply Careful design is required to ensure reliable adequate cooling GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 27 PREVAILING WINDS VENTILATING FAN x SAR 22722 2222 22 2222 rrt I 7777277777272 4 L A A ENGINE MOUNTED FLEXIBLE RAW WATER HEAT EXCHANGER WATER CONNECTIONS SUPPLY FIGURE 25 FACTORY MOUNTED HEAT EXCHANGER COOLING GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net neratorJoe Remote Radiator Application of a remote radiator to cool the engine requires careful design Figures 26 28 and 29
5. STANDBY GENERATOR SET INSTALLATION OPERATION amp MAINTENANCE MANUAL GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net INDEX Introduction Pages 2 4 are blank Safety Pages 6 15 Installation Pages 16 18 Exhaust Pages 19 24 Cooling System Pages 25 39 Ventilation Pages 40 43 Fuel System Pages 44 49 Electrical Installation Pages 50 60 Operation Page 61 Maintenance amp Service Pages 62 63 Troubleshooting Page 64 Warranty Pages 65 66 GeneratorJoe GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe SAFETY PLEASE REVIEW THE FOLLOWING BEFORE PROCEEDING WITH INSTALLATION OR OPERATION OF YOUR GENERATORJOE GENERATOR SET Think Safety first at all times and when in doubt call GENERATORJOE and get additional information before performing installation operation service or testing of the generator set Each section of this manual will have caution and warning information which should be regarded with the utmost care Repairs should only be done by properly trained personnel and under no circumstances should anyone proceed with a repair when they are not sure of proper procedure This manual is not intended to be all that is required to properly operate this unit but is merely an aid to performing bas
6. ventilating fans coolant pumps and other accessories required for the set to run GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net 22 AUXILIARY TANK ALTERNATIVE DIEAERATION TYPE RA DATOR VOLUME CAPACITY MUST BE LEAST 15 OF SYSTEM COOLANT VOLUME ENGINE VENT LIN TO ENGINE im fL 1 eet ahaa aaa ca ahah hi GATE OF BALL VALVES TO ISOLATE ENGINE FOR SERVICING FIGURE 28 REMOTE RADIATOR WITH AUXILIARY COOLANT PUMP AND AUXILIARY TANK Remote Radiator with Hot Well A remote radiator with a hot well Figure 29 can be used if the elevation of the radiator above the crankshaft centerline exceeds the allowable coolant static head on the generator set Specification Sheet In a hot well system the engine coolant pump circulates coolant between engine and hot well and an auxiliary pump circulates coolant between hot well and radiator A hot well system requires careful design In addition to the considerations under Remote Radiator consider the following The bottom of the hot well should be above the engine coolant outlet Coolant flow through the hot well radiator circuit should be approximately the same as coolant flow through the engine The radiator and the auxiliary pump must be sized accordingly Pump head must be sufficient to overcome the sum of the
7. 150 ft 40 ft 10 ft 200 ft 2 The length of pipe to the farthest set will be the only length used when referring to Tables 14 and 15 In this case refer to the 200 ft column in Table 14 natural gas 3 The 50 foot length of pipe serving generator set B alone supplies 890 cfh of gas This section will therefore have to be 2 1 2 inch pipe 4 The 10 foot length of pipe serving generator set A alone supplies 890 cfh of gas This section will also have to be 2 112 inch pipe 5 150 foot length of pipe serving both generator sets supplies 1780 cfh of gas This section will therefore have to be 3 inch pipe 6 When piping is sized on this basis the pressure loss should not be more than 0 5 inches 13 mm WC This procedure can be used when other types of equipment such as the building heating boilers are also supplied by the service pressure regulator supplying the generator sets Note that Tables 14 and 15 cover gas supply pressures not greater than 1 2 psig See NFPA 54 for gas pipe capacity tables for higher gas supply pressures 1 5 10 20 and 50 psig TABLE 14 NATURAL GAS PIPE CAPACITY CUBIC FEET OF GAS PER HOUR NOMINAL LENGTH OF PIPE IN FEET IRON PIPE SIZE 10 20 30 40 50 60 70 80 90 100 125 150 175 200 INCHES 3 4 360 250 200 170 151 138 125 118 110 103 93 84 TI 72 1 680 465 375 320 285 260 240 220 205 195 175 160 145 135 1 1 4 1400
8. 174 C FREEZING 32 F 10 F 6 27 F 56 F 70 F POINT 0C 120 2190 390 490 570 PROPYLENE GLYCOL BOILING 212 F 216 219 222 225 320 F POINT 100 102 C 10426 10696 107 C 160 C Coolant Heaters Thermostatically controlled engine coolant heaters are usually required for starting For Level 1 emergency power systems NFPA 110 requires that engine coolant be kept at a minimum of 90 F 32 C Engine coolant heaters must be connected to the normal power source GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe VENTILATION Ventilation of the generator room is necessary to remove the heat and fumes dissipated by the engine generator and its accessories and to provide combustion air Factory mounted Radiator Ventilation In this configuration Figure 31 the fan draws air over the set and pushes it through the radiator which has flanges for connecting a duct to the out of doors Consider the following See the generator set Specification Sheet for the design airflow through the radiator allowable airflow restriction and minimum air inlet and outlet opening areas The allowable airflow restriction must not be exceeded The static pressure air flow restriction should be measured as shown in Figures 31 and 3
9. Factory Mounted Heat Exchanger The engine pump and liquid to liquid heat exchanger form a closed pressurized cooling system The engine coolant and raw cooling water do not mix Consider the following The installation will require a powered ventilating system See Ventilation in this section obtain net power available from the generator set add the fan load indicated on the generator set Specification Sheet to the power rating of the set and subtract the power consumed by the remote radiator fan ventilating fans coolant pumps and other accessories required for the set to run A pressure reducing valve must be provided if water source pressure exceeds the heat exchanger pressure rating on the generator set Specification Sheet heat exchanger and water piping must be protected from freezing if the ambient temperature can fall below 32 F 0 C Recommended options include a thermostatic water valve non electrical to modulate water flow in response to coolant temperature and a normally closed NC battery powered shut off valve to shut off the water when the set is not running e There must be sufficient raw water flow to remove the Heat Rejected To Coolant indicated on the generator set Specification Sheet Note that a gallon of water absorbs approximately 8 Btu each 1 F rise in temperature specific heat Also it is recommended that the raw water leaving the heat exchanger not exceed 140 F 60
10. medical attention Do use the correct tools for the job you are doing Do make sure that all fasteners are secure Do use extreme care while making adjustments on the generator set while it is running Do keep your hands away from moving parts Do remember Horseplay is for horses It has no place around machinery Do disconnect batteries before starting work on generator set Do use screwdrivers pliers diagonal pliers etc with insulated handles Do remember to keep one hand in your pocket if it is necessary to work on live circuits To do so will prevent passage of electricity into one hand and out the other which passes current across the heart SAFETY DO S AND DON TS DO PRACTICE SAFETY The life you save may be your own DON T Don t allow inexperienced personnel to work on the generator or electrical equipment Don t remove plastic guards or protective devices Don t wear loose clothing or jewelry in the vicinity of moving parts These can get in machinery with disastrous results Don t wear jewelry while working on electrical equipment If your hair is long wear a head covering Hair caught in a drill press fan belt or other moving parts can cause serious injury Don t stand on a wet floor while working on electrical equipment Use rubber insulated mats placed on dry wood plat forms Don t lunge after a dropped tool do so may place you in a position of extreme
11. voltage Making line or auxiliary connections Hazardous voltage can cause severe injury or death To prevent electrical shock deenergizethe normal power source before making any line or auxiliary connections Servicing the transfer switch Hazardous voltage can cause severeinjury or death Deenergize all power sources before servicing Open the main circuit breakers of all transfer switch power sources and disable all generator sets as follows 1 Move all generator set master controller Switches to the OFF position 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads lastwhen reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatictransfer switch remote start stop switch or engine start command from a remote computer Before servicing any components inside the enclosure 1 Remove rings wristwatch and jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Generator Joe 11 Servicing the transfer switch controls and accessories within the enclosure Hazardous voltage can cause severe injury or death Disconnectthe transfer
12. 950 770 660 580 530 490 460 430 400 360 325 300 280 1 1 2 2100 1460 1180 990 900 810 750 690 650 620 550 500 460 430 2 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 1020 950 850 800 2 1 2 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 1650 1500 1370 1280 3 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 2950 2650 2450 2280 Based 0 5 inch 13 mm WC pressure drop 0 60 specific gravity gas and nominal 1 2 psig 3 4 kPa pressure TABLE 15 LPG GAS PIPE CAPACITY CUBIC FEET OF GAS PER HOUR NOMINAL LENGTH OF PIPE IN FEET IRON PIPE SIZE 10 20 30 40 50 60 70 80 90 100 125 150 INCHES 3 4 221 157 126 107 95 87 78 74 69 65 58 53 1 428 293 236 201 179 164 151 138 129 123 110 101 1 1 4 882 598 485 416 365 333 308 289 207 252 230 204 1 1 2 1323 920 743 624 567 570 472 434 409 390 346 315 2 2488 1732 1386 1197 1058 958 882 819 768 724 642 598 Based on 0 5 inch 13 mm WC pressure drop and nominal 11 inch 280mm WC pressure at inlet GeneratorJoe Electrical Installation ENGINE STARTING SYSTEMS Battery Starting Systems e Battery starting systems for generator sets are usually 12 volt or 24 volt Figure 36 illustrates typical battery starter connections Consider the following e Batteries must have enough capacity to provide the cranking motor current indicated on the gen
13. AMD THE PROPANE GAS SOIL VALVE OREM UPON LOSS GF RT DIAS BY PAEIESUBE TO CONTINLIE GENERATOR SET OPERATION WITHONJT TERA TIO RETURN TOA GAS E MITCIMUTIC WHEN SUPPLY 16 BRESTCPIEZ FIGURE 34 TYPICAL GASEOUS FUEL SYSTEM GeneratorJoe e LPG vaporizer heated by engine coolant is factory installed on GeneratorJoe generator sets equipped for a liquid withdrawal of LPG Because high pressure gas piping liquid or vapor is not permitted inside buildings generator sets equipped for liquid withdrawal of LPG must not be Installed inside the building Weather protective housings for outdoor installation are available for most models e Ambient temperature affects the rate of vaporization in an LPG supply tank In colder climates a way to compensate for the reduced rate of vaporization is to install a larger supply tank Table 13 can be used as a quick reference for sizing the propane tank to account for expected low ambient temperatures The required rate of vaporization can also be obtained by means of a burner type or engine coolant type LPG vaporizer located Just outside the building TABLE 13 MINIMUM PROPANE TANK SIZE IN GALLONS LITERS FOR REQUIRED VAPORIZATION LOWEST AVERAGE WINTER TEMPERATURE WITHDRAWAL RATE Tank must be at least 32 F 20 F 10 F 0 F 10 F 20 F half full 0 C 7 C 12 C 1 C 23 C 29 C 100 cfh 100 150 200 250 400 650 3
14. D FLEX PIPE I D HOSE INCHES HOSE INCHES HOSE INCHES HOSE INCHES SIZE MM SIZE MM SIZE MM SIZE MM 0 15 NO 6 5 16 7 9 NO 6 13 32 10 3 NO 4 3 16 4 8 NO 6 5 16 7 9 15 20 NO 8 13 32 10 3 NO 8 1 2 12 7 NO 4 3 16 4 8 NO 6 5 16 7 9 20 80 NO 10 1 2 12 7 NO 10 5 8 15 9 NO 8 13 32 10 3 NO 10 1 2 12 7 80 100 NO 12 5 8 15 9 NO 16 7 8 22 3 NO 8 13 32 10 3 NO 10 1 2 12 7 100 160 NO 16 7 8 22 3 NO 16 7 8 22 3 NO 10 1 2 12 7 NO 12 5 8 15 9 160 gt NO 16 7 8 22 3 NO 16 7 8 22 3 NO 12 5 8 15 9 NO 12 5 8 15 9 Based on four straight fittings two 90 fittings and minimal fuel lift height Separate fuel return lines to the day tank or supply tank must be provided for each generator set in a multiple set installation to prevent the return lines of idle sets from being pressurized Also a fuel return line must not include a shutoff device Engine damage will occur if the engine is run when the line is shut off A day tank is required whenever pipe friction and or supply tank elevation either below the fuel pump inlet or above the fuel injectors would cause an excessive fuel inlet or return restriction Some generator set models are available with an integral skid mounted or sub base day tank For critical start applications where generator sets are paralleled or must satisfy emergency start time requirements it is recommended that a fuel tank or reservoir be locat
15. ECM when the POWER ON lightislit Ensure that the generator set and day tank are electrically grounded Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a_ utility electrical system can cause serious injury or death to utility personnel working on power lines Installing accessories to the transformer assembly Hazardous voltage can cause severe injury or death To prevent electrical shock disconnect the harness plug before installing accessories that will be connectedto the transformer assembly primary terminals on microprocessor logic models Terminals are at line
16. Joe T b 20 e Exhaust backpressure must not exceed the allowable back pressure on the generator set Specification Sheet Excessive exhaust backpressure reduces engine power and engine life and may lead to high exhaust temperatures and smoke Engine exhaust back pressure should be estimated before the layout of the exhaust system is finalized and it should be measured at the exhaust outlet under full load operation before the set is placed in service Example Calculation The layout of an exhaust system similar to that shown in Figure 21 calls for a 5 inch diameter by 24 inch long flexible tube at the engine exhaust outlet a critical grade muffler with a 6 inch diameter inlet 20 feet of 6 inch diameter pipe and one 6 inch diameter long radius elbow The generator set Specification Sheet indicates that the engine exhaust gas flow is 2 715 cfm cubic feet per minute and that the maximum allowable exhaust backpressure is 41 inches WC Water Column This procedure involves determining the exhaust backpressure caused by each element flexible tubes mufflers elbows and pipes and then comparing the sum of the backpressures with the maximum allowable backpressure 1 Determine the exhaust backpressure caused by the muffler Figure 22 is a graph of exhaust backpressures for mufflers made available by GeneratorJoe If the muffler is from another source it will be necessary to obtain equivalent data from the muffler manufacturer To use Figure 2
17. Slot Width gt 1 2 mm 0 047 in Split Bolt Other AWG kcmil mm Slot Length 6 4 mm 0 25 in Slot Length gt 6 4 mm 0 25 in Connectors Connections 18 10 0 82 5 3 2 3 20 4 0 85 90 80 8 5 75 8 8 4 2 8 25 4 5 40 90 80 8 5 75 6 4 13 3 21 2 4 0 35 5 1 45 186 165 12 4 110 3 26 7 4 0 35 5 6 50 311 275 16 9 150 2 33 6 4 5 40 5 6 50 31 1 275 16 9 150 1 42 4 5 6 50 311 275 16 9 150 1 0 2 0 53 5 67 4 5 6 50 43 5 385 20 3 180 3 0 4 0 85 0 107 2 5 6 50 56 5 500 282 250 250 350 127 177 5 6 50 73 4 650 36 7 325 400 203 5 6 50 93 2 825 36 7 325 500 253 5 6 50 93 2 825 42 4 375 600 750 304 380 5 6 50 113 0 1000 42 4 375 800 1000 406 508 5 6 50 124 3 1100 56 5 500 1250 2000 635 1016 124 3 1100 67 8 600 For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Note If aconnector has a clamp screw such as a slotted hexagonal head screw with more than one means of tightening test the connector using both applicable torque values Tightening Torque for Screw Type Pressure Wire Connectors Socket Size Across Flats Tightening Torque mm in Nm i
18. approved by the authority having jurisdiction see NFPA No 54 e Most installations will require a service gas pressure regulator Typically gas supply pressure should not exceed 20 inches 508 mm WC at the Inlet to the generator set Depending on distribution gas pressure more than one stage of pressure regulation may be required High pressure gas piping is not permitted inside buildings Gas pressure regulators must be vented to the out of doors according to code e Approved flexible fuel hose must be used for connections at the engine to take up generator set movement and vibration Some GeneratorJoe generator set models are equipped with flexible hoses that are connected to bulkhead fittings on the skid where solid pipe connections can be made by the installer Most codes require both manual and electric battery powered shutoff valves ahead of the flexible fuel hose s The manual valve should be of the indicating type e A dry fuel filter should be installed in each line as shown In Figure 34 to protect the sensitive pressure regulating components and orifices downstream from harmful foreign substances carried along in the gas stream rust scale etc LPG fuel supply system must be dedicated for the emergency power system if it is the required alternate fuel GeneratorJoe 46 GAS 5 TCI 20 LBE 34 ZO KP Ie LET PRESSURE THE UR SAITOH CAUSES THE HATUPAL GAS SOLENORD VALVE TO GLOGE
19. are not limited to the following Light headedness dizziness Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Fuel System WARNING b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble The
20. geographic area plus 596 for handling GeneratorJoe will provide replacement parts to claimant s location within the continental United States If claimant is located outside the continental United States all parts shipments are f o b point of debarkation In the event warranty repairs are affected outside the boundaries of the United States of America GeneratorJoe is not responsible for any duties taxes or associated charges as may be applicable in accordance with the regulations of the country where such warranty repair is performed All claims must be brought to the attention of GeneratorJoe or an authorized distributor or its designated service representative within thirty 30 days after the discovery that goods or parts fail to meet this warranty Engine manufacturers warranty The engine manufacturer issues its own separate warranty covering the engines performance and parts In the event of an engine related failure GeneratorJoe can refer you to an engine authorized service center This warranty does not apply to Cost of maintenance adjustments installation and start up Failures due to accident misuse abuse negligence or improper replacement Damage due to faulty repairs not performed by an authorized service representative Products which are altered or modified in a manner not authorized by manufacturer in writing Failure of goods caused by defects in the system or application in which the goods are installed Failure cause
21. lengths of all fittings and valves by using Table 9 and add to the total run of straight pipe Three Long Sweep Elbows 3 X 5 2 iana EEEE uhr 15 6 Two Gate Valves Open U 2 x 1 7 eee tee A S EUER 3 4 Tee Straight RUD UNS ea OUR Re OR e us 5 2 60 Feet Straight Pipe ert rete rev ep BN TRU MULA 60 0 EQUIVALENT LENGTH OF PIPE 84 2 3 Find the backpressure at the given flow per unit length of pipe for the nominal pipe diameter used in the system In this example 3 inch nominal pipe is used Following the dashed lines in Figure 30 3 inch pipe causes a pressure loss of approximately 1 65 psi per 100 foot of pipe 4 Calculate the pressure loss in the piping as follows 1 65 psi Piping Loss 84 2 feet x 100 feet 1 39 psi 5 total system loss is the sum of the piping and radiator losses Total Pressure Loss 1 39 psi piping 1 00 psi radiator 2 39 psi 6 The calculation for this example indicates that the layout of the remote radiator cooling system is adequate in terms of coolant friction head since it is not greater than the allowable friction head If a calculation indicates excessive coolant friction head repeat the calculation using the next larger pipe siz
22. proportional to the total heat input divided by the allowable room air temperature rise 58 x Total Heat Btu min Required Air Flow 38x7920 15312 cfm Temp Rise A F 30 TABLE 11 HEAT LOSSES FROM UNINSULATED EXHAUST PIPES AND MUFFLERS PIPE DIAMETER HEAT FROM PIPE Heat From Muffler INCHES mm BTU MIN FOOT kJ Min Metre BTU MIN kJ Min Metre 1 5 38 47 162 297 313 2 51 57 197 490 525 2 5 64 70 242 785 828 3 76 84 291 1 100 1 160 3 5 98 96 332 1 408 1 485 4 102 108 374 1 767 1 864 5 127 132 457 2 500 2 638 6 152 156 540 3 550 3 745 8 203 200 692 5 467 5 768 10 254 249 862 8 500 8 968 12 305 293 1 014 10 083 10 638 GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe FUEL SUPPLY Diesel Fuel The following should be considered when installing a diesel fuel supply system Fuel supply tank construction location installation venting piping testing and inspection must comply with applicable codes See NFPA Standards No 30 and No 37 Fuel supply tanks must be adequately vented to prevent pressurization have provisions for manually draining or pumping out water and sediment and have at least a five percent expansion space to prevent fuel spillage when the fuel heats up and expands
23. severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 80unces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both preventbubble formation A successful test depends on the ability of the solution to bubble Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Electrical Shock DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure over 600 volts DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing over 600 volts AN WARNING Hazardous voltage Can cause severe injury or death Disconnect all power sources before servicing Install the barrier after adjustments maintenance or servicing 600 volts and under WARNING Hazardous voltage Can
24. static and friction heads in the hot well radiator circuit One foot of pump head pump manufacturer s data is equivalent to 0 43 PSI of coolant friction head pressure loss or one foot of coolant static head height of liquid column The liquid holding capacity of the hot welt should not be less than the sum of the following volumes e 1 4 of the coolant volume pumped per minute through the engine eg 25 gallons if the flow is 100 gpm plus e 1 4 of the coolant volume pumped per minute through the radiator eg 25 gallons if the flow is 100 gpm plus Volume required to fill the radiator and piping plus Five percent of total system volume for thermal expansion Careful design of the inlet and outlet connections and baffles is required to minimize coolant turbulence allow free deareation and maximize blending of engine and radiator coolant flows Coolant must be pumped to the bottom tank of the radiator and returned from the top tank otherwise the pump will not be able to completely fill the radiator The auxiliary pump must be lower than the low level of coolant in the hot well so that it will always be primed The radiator should have a vacuum relief check valve to allow drain down to the hot well The hot well should have a high volume breather cap to allow the coolant level to fall as the auxiliary pump fills the radiator and piping To obtain the net power available from the generator set add the fan load indicated on
25. switch controls at the inline connector to deenergize the circuit boards and logic circuitry but allow the transfer switch to continue to supply power to the load Disconnect all power sources to accessories that are mounted within the enclosure but are not wired through the controls and deenergized by inline connector separation Test circuits with a voltmeter to verify that they are deenergized before servicing Heavy Equipment WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Use adequate lifting capacity Never leave the transfer switch standing upright unless it is securely bolted in place or stabilized Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation C
26. system Monthly e Checking for air cleaner restrictions e Exercising the generator set by starting it and running it for at least 30 minutes under not less than one half rated load and checking for unusual vibrations noises and exhaust coolant and fuel leaks while the set is running Regular exercising keeps engine parts lubricated improves starting reliability prevents oxidation of electrical contacts and consumes fuel before It deteriorates and has to be disposed of e Checking for radiator restrictions coolant leaks deteriorating hoses loose and deteriorating fan belts non functioning motorized louvers and concentration of engine coolant conditioner e Checking for holes leaks and loose connections in the air cleaner e Checking fuel level and fuel transfer pump operation e Checking for exhaust system leaks and restrictions and draining the condensate trap e Checking all meters gauges and Indicator lamps for proper operation e Checking the battery cable connections and recharging the batteries if specific gravity is less than 1 260 e Checking for ventilation restrictions in the inlet and outlet openings of the generator e Checking that all required service tools are readily available Semi Annually e Changing engine oil and the full flow and the by pass oil filters e Changing the filter s in the coolant conditioner circuit e Cleaning or replacing the crankcase breather filter s e Changing the fuel filter s drai
27. technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals Accidental Starting WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command froma remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locatethe battery in a well ventilated area Isolate the battery charger from ex
28. the generator set Specification Sheet to the power rating of the set and subtract the power consumed by the remote radiator fan ventilating fans coolant pumps and other accessories required for the set to run GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe BREATHER CAP BAFFLES ENGINE VENT LINE HOT uu COOLANT AUXILIARY COOLANT PUMP FOR ake URN HOT WELL RAGIATOR CIRCUIT FIGURE 29 REMOTE RADIATOR WITH HOT WELL AND AUXILIARY COOLANT PUMP GeneratorJoe Example Pipe Sizing Calculations for Remote Radiator Heat Exchanger Systems The preliminary layout of piping for a remote radiator cooling system similar to the one shown in Figure 26 calls for 60 feet of 3 inch diameter pipe three long sweep elbows two gate valves to isolate the radiator for engine servicing and a tee to connect the fill makeup line The generator set Specification Sheet indicates that coolant flow is 123 GPM and that the allowable friction head is 5 PSI This procedure involves determining the pressure loss friction head caused by each element and then comparing the sum of the pressure losses with the maximum allowable friction head 1 Determine the pressure loss in the radiator by referring to the radiator manufacturer s data For this example assume the pressure loss is 1 psi at a flow of 123 gpm 2 Find the equivalent
29. this warranty your purchase must be registered within 30 days of initial Start up warranty registration form to be provided and completed by seller 2 GeneratorJoe s liability and purchaser s sole remedy for a failure of goods under this warranty and for any and all other claims arising out of the purchase and use of goods including negligence on the part of the manufacturer shall be limited to the repair of the product by the repair or replacement at GeneratorJoe s option of parts that do not conform to this warranty provided that the 5 product or parts are returned as requested to GeneratorJoe s factory as shown on the GeneratorJoe website or to a GeneratorJoe s authorized distributor or its designated service representative transportation pre paid For generators that have been permanently mounted travel shall be allowed up to a maximum of 300 miles round trip and a maximum of 7 hours travel time In the event warranty repairs are not performed by a GeneratorJoe authorized distributor or its designated service representative said warranty repair claim will be administered through GeneratorJoe s Warranty Department and claimant will be reimbursed labor expenses at the rate of thirty 30 U S dollars per hour for the time allowed for applicable repair or for the actual labor expense whichever is less Parts will be reimbursed at GeneratorJoe s current list price less the applicable discount from the parts depot in the local
30. to start can be prevented if proper maintenance is performed on a scheduled basis Other troubleshooting is provided in each of the operator guides supplied with the unit and should be reviewed for other problem solving GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 64 GeneratorJoe GeneratorJoe Generator Sets GeneratorJoe MANUFACTURER S LIMITED WARRANTY extends to the original purchaser of goods for use the following warranty covering goods manufactured or supplied by GeneratorJoe subject to the qualifications indicated in this document There is no other express warranty This document covers warranties on products only and any other matters concerning sales or rentals of equipment or products supplied by GeneratorJoe shall be governed by GeneratorJoe s polices as posted on www generatorjoe net which is subject to change without notice at any time Implied warranties including merchantability and fitness for a particular purpose are limited to periods of warranty set forth below and to the extent permitted by law any and all implied warranties are excluded In no event is GeneratorJoe liable for incidental or consequential damages NOTE Some states do not allow limitations on how long an implied warranty lasts so the above limitations may not apply in every instance 1 Generat
31. 2 a Find the cross sectional area of the muffler inlet using Table 7 0 1963 ft in this example b Find exhaust gas velocity in feet per minute fpm by dividing exhaust gas flow cfm by the area of the muffler inlet as follows 2 715 cfm Gas Velocity 13 831 0 1963 ft c Inthis example the dashed lines in Figure 22 show that the critical grade muffler will cause a backpressure of approximately 21 5 inches W C TABLE 7 CROSS SECTIONAL AREAS OF OPENINGS OF VARIOUS DIAMETER DIAMETER OF AREA OF DIAMETER OF AREA OF MUFFLER MUFFLER MUFFLER MUFFLER INLET INCHES INLET INLET INCHES INLET FT2 2 0 0218 5 0 1363 2 5 0 0341 6 0 1963 3 0 0491 8 0 3491 3 5 0 0668 10 0 5454 4 0 0873 12 0 7854 GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 21 8 o BRHEERE A 27 Sea Nu 24 4 4 T S EXHAUST GAS VELOCITY FEET MINUTE FIGURE 22 TYPICAL MUFFLER EXHAUST BACK PRESSURE VS GAS VELOCITY GeneratorJoe _ EXHAUST BACK PRESSURE INCHES WATER COLUMN SEE NUNS T FT HE SSE PENS 12 14 00 6 2 Find the equivalent lengths of all fi
32. 2 1505 951 821 753 602 151 109 87 600 750 2084 1971 1806 1141 985 903 723 181 131 104 750 938 2605 2463 2258 1426 1232 1129 903 226 164 130 800 1000 2779 2627 2408 1521 1314 1204 963 241 175 139 900 1125 3126 2956 2710 1711 1478 1355 1084 271 197 156 1000 1250 3474 3283 3011 1901 1642 1505 1204 301 219 174 1100 1375 2092 1806 1656 1325 331 241 191 1200 1500 2282 1971 1806 1445 361 263 208 1250 1563 2377 2053 1882 1505 376 274 217 1500 1875 s 2852 2463 2258 1806 452 328 261 GeneratorJoe Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation Because of the large number of accessories and possible combinations this manual does not address specific applications Refer to the submittal catalog accessory drawings and wiring diagrams for connection location Most field installed accessory kits include installation instructions For customer supplied wiring select the wire temp rating in chart below based on the following criteria Temp Rating 60 C 140 F Use No AWG 60 C or wire or use No AWG 75 C 167 F 75 C wire Copper Cu Only Cu Aluminum Al Combinations Use 60 C wire
33. 2 to confirm before the set is placed in service that the system is not too restrictive especially when ventilating air is supplied and discharged through long ducts restrictive grilles screens and louvers Refer to the ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers publications for recommendations on duct design if air ducts are required for the application Note that the inlet duct must handle combustion airflow see the Specification Sheet as well as ventilating airflow and must be sized accordingly PREVAILING WINDS ENGINE DRIVEN THERMOS TATIGALLY FAN CONTROLLED LOUVER M 5 S N bN S x DSHS SAS 5 SS c a ae FI o 2 MEASURE STATIC PRESSURE md WITHIN 6 INCHES 150 mm OF THE FLEXIBLE DUCT OUTLET AIR NOT LESS THAN RADIATOR SEE FIGURE 32 CONNECTOR DAMPER HEIGHT OF RADIATOR FIGURE 31 FACTORY MOUNTED RADIATOR COOLING GeneratorJoe e Louvers and screens over air inlet and outlet openings restrict airflow and vary widely in performance A louver assembly with narrow vanes for example tends to be more restrictive than one with wide vanes The effective open area specified by the louver or screen manufacturer should be used The airflow through the radiator is usually sufficient for generator room ventilation See the example calculation for a method of determ
34. 21 TYPICAL EXHAUST SYSTEM 19 Pipe bend radii should be as long as practical It is recommended that as far as is possible and consistent with the exhaust back pressure limitations of the engine exhaust tubing and piping of the same nominal diameter as the engine exhaust outlet be used throughout the exhaust system Piping of smaller diameter than the exhaust outlet must never be used Piping that is larger than necessary is more subject to corrosion due to condensate than smaller pipe and reduces the exhaust gas velocity available for dispersing the exhaust gases up and into the outdoor wind stream Also as a rule the fewer pipe diameter changes in the exhaust system the less friction loss It is recommended that all exhaust piping and mufflers be thermally insulated to prevent burns from accidental contact prevent activation of tire detection devices and sprinklers reduce corrosion due to condensate and reduce the amount of heat radiated to the generator room Engine exhaust manifolds and turbocharger housings unless water cooled must never be insulated Doing so can result in material temperatures that can destroy the manifold and turbocharger Exhaust piping must be routed at least 9 inches 229 mm from combustible construction Use approved thimbles where exhaust piping must pass through combustible walls or ceilings Exhaust pipe steel expands approximately 0 0076 inches per foot of pipe for every 100 F rise in exhaust gas te
35. CURFENT PROTECTION OF FACA THE LOAD SIDE OF THE PRST PERORITY ATS THE ITEMS IN TALES ARE HOT ALWAYS USED FIGURE 40 TYPICAL GENERATOR SET CONTROL AND ACCESSORY WIRING GeneratorJoe _ Allowable Single Phase Load Unbalance Single phase loads should be distributed as evenly as possible between the three phases of a three phase generator set in order to fully utilize the rated capacity kVA and kW of the set and to limit voltage unbalance Figure 41 can be used to determine the maximum permissible percentage of unbalanced single phase load as illustrated by the example calculation Single phase power can be taken up to 67 percent of the three phase rating on GeneratorJoe generator sets not larger than 175 kW Note that this will result in line currents for Y connected generators that will exceed nameplate ratings by approximately 15 percent Generally the larger the generator set the lower the percentage of single phase power that can be taken Figure 41 includes single phase percentage lines for GeneratorJoe intermediate size Frame 4 and Frame 5 generators Confirm the frame size by referring to the applicable Alternator Data Sheet referenced by the generator set Specification Sheet For generator sets rated more than 500kW load unbalance should not exceed 10 percent Example Calculation Find the maximum single phase load that can be powered in conjunction with a total three phase load of 62 kVA by a generator set rated 100k
36. RESSURE LOSSES FOR INCH mm DIAMETER PIPES 8 UTE ETT ee ii A TELLE LLL LLLI 38 Coolant Treatment Antifreeze ethylene or propylene glycol base and water are mixed to lower the freezing point of the cooling system and to raise the boiling point Refer to Table 10 to determine the concentration of ethylene or propylene glycol necessary for protection against the coldest ambient expected Antifreeze water mixture percentages in the range of 30 70 to 60 40 are recommended for most applications Propylene glycol based antifreeze is less toxic than ethylene based antifreeze offers superior liner protection and eliminates some fluid spillage and disposal reporting requirements Diesel generator sets may be equipped with replaceable coolant filtering and treating elements to minimize coolant system fouling and corrosion They are compatible with most antifreeze formulations For smaller sets the antifreeze should contain a corrosion inhibitor TABLE 10 FREEZING AND BOILING POINTS VS CONCENTRATION OF ANTIFREEZE MIXTURE PERCENTAGES ANTIFREEZE WATER MIXTURE BASE 0 100 30 70 40 60 50 50 60 40 95 5 FREEZING 32 F 4 10 34 65 8 F 0C 16 230 36 C 54 C 13 C ETHYLENE GLYCOL BOILING 2129 220 F 222 226 F 230 F 345 POINT 100 10420 1062 1086 11090
37. Total cable length is 375 inches including the cable between the batteries There are six cable connections The generator set Specification Sheet indicates that cranking motor current is 565 amps Calculate the required cable size as follows 1 2 3 Assume a resistance of 0 0002 ohms for the starter solenoid contact Assume a resistance of 0 00001 ohms for each cable connection six Based on the formula that R ohms volts L amperes Allowable Cable Resistance Allowable Voltage Drop Sum of Other Resistance Cranking Amps 2 0 0002 0 00001 0 00328 ohms 565 Refer to Figure 37 for AWG American Wire Gauge cable resistances In this example as shown by the dashed lines 40 AWG is the smallest cable size that can be used FIGURE 37 RESISTANCE vs LENGTH FOR VARIOUS AWG CABLE SIZES A al R aa LI l x IDA ee pri Iur 5 ETT 1 5 i ___ 100 200 300 AUD 500 600 2 54 5 08 10 18 12 70 15 24 17 76 LENGTH OF GABLE IN INCHES METRES GeneratorJoe Air Starting Systems Figure 38 shows a piping arrangement for a typical air starter The following items should be considered when installing an air starter system e The engine manufacturer should be consulted for recommendations regarding air hose size and the minimum tank volume required for each second of cranking Tank size wil
38. W 125 kVA 1 Find the three phase load as a percentage of the generator kVA rating Three Phase Load Percentage 62 kVA 125 100 50 2 Find the percentage of allowable single phase load as shown by the arrows in Figure 41 In this case it is approximately 34 percent of the three phase rating 3 Find the maximum single phase load Maximum Single Phase Load 125 x 34 42 5 100 4 Note as follows that the sum of the three phase and maximum permissible single phase loads is less than the kVA rating of the generator set 62 kVA 3 Phase Load 42 5 kVA 1 Phase Load 104 5 kVA and 104 5 kVA lt 125 kVA Rating of the Generator Set Unbalanced loading of a generator set causes unbalanced phase voltages The levels of load unbalance anticipated by these guidelines should not result in harm to the generator set itself The corresponding levels of voltage unbalance however may not be acceptable for loads such as three phase motors Because of unbalanced phase voltages critical loads should be connected to the phase which the voltage regulator uses as the reference voltage L1 L2 as defined in the generator set schematic when only one phase is used as a reference All three phases are used for voltage reference on GeneratorJoe PMG excited generators with 3 phase sensing option GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales ge
39. acid that forms when the sulfur in the fuel combines with tank condensate resulting in debris that can clog fuel pumps and filters Although copper has been used for diesel fuel lines for many years black iron pipe is preferred Diesel fuel polymerizes thickens in copper tubing during long periods of standby with the result that fuel injectors can clog GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe The generator set Specification Sheet indicates the maximum fuel inlet and return restrictions the maximum fuel flow and the fuel consumption Table 12 indicates minimum hose and pipe sizes for connections to a supply tank or day tank that is relatively close to the set and at approximately the same elevation Hose and pipe size should be based on the maximum fuel flow rather than on the fuel consumption The maximum fuel flow is approximately twice the full load fuel consumption on GeneratorJoe generator sets rated 200 175 kW and larger It is highly recommended that the fuel Inlet and return restrictions be checked before the set is placed in service TABLE 12 MINIMUM FUEL SUPPLY HOSE AND PIPE SIZES 0 10 EVE 10 50 0 n FEET 10 50 FEET MAXIMUM 0 3 METRES 3 15 METRES 0 3 METRES 3 15 METRES GPH FLEX PIPE I D FLEX PIPE I D FLEX PIPE I
40. allation or operation of the GENERATORJOE generator set The following page lists some of the safety dos and don ts that everyone should remember GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service
41. ater pump belt when the generator set is running If it s necessary to run the generator with the end cover removed by very careful with tools or meters being used in that area to avoid contacting the rotor Battery Hazards Few people realize just how dangerous a battery can be The electrolyte in a lead acid battery is dilute sulphuric acid H5504 During charge or discharge functions of a battery a chemical change takes place within the individual cells that causes the bubbling we see through the filler hole This gas bubbling is hydrogen and oxygen and it is EXPLOSIVE If during this gassing action a means of ignition is present an explosion could occur A defective battery may suddenly explode even while standing idle Added to this danger consider a fall out of highly corrosive sulphuric acid caused by the explosion A rubber blanket or other cover can be used to reduce the risk from possible explosion Precautions Always wear eye protection when servicing batteries If electrolyte is splashed on the skin or in the eyes flush immediately under running water Obtain medical help as soon as possible When charging batteries do not remove the vent caps When disconnecting or reconnecting the generator set battery make sure the on off switch is in the off position to prevent an arc which could cause the battery to explode Disconnect the ground cable first preferably at a point away from the battery Reconnect t
42. ation transmitted Locate the isolators as shown on the generator set outline drawing referenced on the Specification Sheet The outline drawing may show configurations involving 4 6 8 or 12 point mounting Also when the generator set is mounted on top of a sub base fuel tank the vibration isolators must be installed between the generator set and the fuel tank Bolting these generator sets directly to the floor or foundation will result in excessive noise and vibration and possible damage to the set the floor and other equipment Smaller GENERATORJOE generator sets have rubber vibration isolators located between the skid and the engine generator assembly They may be bolted directly to the foundation floor or sub structure FIGURE 19 TYPICAL STEEL SPRING VIBRATION ISOLATOR 16 Mounting on a Slab Floor When a generator set is mounted on a concrete slab floor a concrete pad should be poured on top of the floor The pad should be reinforced concrete with a 28 day compressive strength of at least 2500 psi 173 kPa It should be at least 6 inches 150 mm deep and extend at least 6 inches 150 mm beyond the skid on all sides Type J or L bolts should be used to anchor the skid or vibration isolators to the pad Mounting on a Sub Base Fuel Tank When a generator set is mounted on a sub base fuel tank the vibration isolators must be installed between the generator set and the fuel tank The fuel tank must be able to support th
43. buretor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Exhaust System A WARNING Carbon monoxide cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Copper tubing exhaust systems Carbon monoxide can cause severe nausea fainting or death Do not use copper tubing in diesel exhaust systems Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust leakage Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep backinside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but
44. cause severe injury or death Disconnect all power sources before opening the enclosure 600 volts and under WARNING Hazardous voltage Moving rotor Can cause severe injury or death GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Operate the generator set only when all guards and electrical enclosures are in place GeneratorJoe A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connec
45. ccesscessees 27 4 5 The calculation indicates that the piping layout is adequate in terms of exhaust backpressure since the sum of the backpressures is less than the maximum allowable backpressure of 41 Inches WC GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net EXHAUST BACK PRESSURE INCHES WATER COLUMN PER FOOT OF PIPE LENGTH An D ERE ERE EL D 2 LJ ud EL 1 LILLLITTTS HH lclclcldLuialiu F tt ATT TTT Sa 1 LIRE 0 1 A LIBE v LLLI acm LIII HEY LS Burro MRR Ht 7 Lo LI Pe eS 2 OTT TTT EXHAUST FLOW CFM GeneratorJoe ENGINE COOLING Liquid cooled engines are cooled by pumping coolant a mixture of water and anti freeze through passages in the engine cylinder block and head s by means of an engine driven pump The engine pump and radiato
46. charge openings should be located or shielded to minimize fan noise and the effects of wind on airflow LEAVE THE OTHER END OF THE MANOMETER OPEN TO THE GENERATOR ROOM PRESSURE 1 4 IN 8 mm COPPER TUBE WITH PLUGGED END AND 1 18 IN 1 5 mm CROSS DRILLED HOLES ORIENT THE TIP PARALLEL WITH THE AIR STREAM IN RADIATOR DISCHARGE DUCT WITHIN amp INCHES 150 mm OF THE RADIATOR INCLINED 0 01 IN WC A ACCURACY FIGURE 32 RECOMMENDED INSTRUMENTATION FOR MEASURING AIR FLOW RESTRICTION Heat Exchanger Or Remote Radiator Ventilation A heat exchanger or remote radiator cooling system might be selected because of noise considerations or because the airflow restriction through long ducts would be greater than that allowed for the engine driven radiator fan Consider the following e Ventilating fans must be provided for the generator room The ventilating fans must have the capacity of moving the required flow of ventilating air against the airflow restriction See the following example calculation for a method of determining the airflow required for ventilation A remote radiator fan must be sized primarily to cool the radiator Depending on its location it might also be used to ventilate the generator room The fan and air inlet locations must be such that the ventilating air is drawn forward over the set To obtain net power available from the generator set add the fan loa
47. d by operations at speeds load or conditions contrary to published specifications or recommendations g Negligent maintenance such as 1 Failure to perform scheduled maintenance 2 Failure to provide sufficient lubricating oil 3 Failure to provide sufficient cooling 4 Failure to keep air intake and cooling fins clean 5 Failure to properly service air cleaner 6 Use of other than factory supplied or approved repair parts and or procedures Telephone Telegraph Teletype or other communication expenses Living and travel expenses of person performing service Rental equipment used while warranty repairs are being performed Overtime labor Batteries Batteries are warranted by the battery manufacturer Starters and battery charging alternators Warranted by Component Manufacturer Consumable items including but not restricted to 1 Engine oil 2 Grease and lubricants Fuel Filters and filter elements Injector nozzles Glow plugs Cleaning materials Belts Light bulbs and fuses 3 4 5 6 7 8 9 10 Antifreeze coolant No person is authorized to give any other warranties or to assure any other liabilities GeneratorJoe s behalf unless made or assumed in writing by an officer of GeneratorJoe and no person is authorized to give any warranties or assume any other liability on behalf of seller unless made or assumed in writing by seller 6 7 This wa
48. d disable all generator sets as follows 1 Move all generator set master controller switches to the OFF position 2 Disconnect power to all battery chargers 3 Disconnect all battery cables negative leads first Reconnect negative leads lastwhen reconnecting the battery cables after servicing Follow these precautions to prevent the starting of generator sets by an automatictransfer switch remote start stop switch or engine start command from a remote computer Before servicing any components inside the enclosure 1 Remove rings wristwatch and jewelry 2 Stand on a dry approved electrically insulated mat 3 Test circuits with a voltmeter to verify that they are deenergized GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net 10 WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply Grounding electrical equipment Hazardous voltage cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator se
49. d indicated on the generator set Specification Sheet to the power rating of the set and subtract the power consumed by the remote radiator fan ventilating fans coolant pumps and other accessories required for the set to run PREVAILING WINDS FIGURE 33 VENTILATION FOR A HEAT EXCHANGER COOLING SYSTEM GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe Example Ventilating Air flow Calculation The generator set Specification Sheet indicates that the heat radiated to the room from the generator set engine and generator is 4 100 BTU min The muffler and 10 feet of 5 inch diameter exhaust pipe are also located inside the generator room Determine the airflow required to limit the air temperature rise to 30 F 1 Add the heat inputs to the room from all sources Table 11 indicates that the heat loss from 5 inch exhaust pipe is 132 BTU per m per foot of pipe and 2 500 BTU per m from the muffler Add the heat inputs to the room as follows Heat from Generator 0 02 0 0 4 4 100 Heat from Exhaust Pipe 10 x 132 2 9 4 1 320 Heat trom Muttlet d e ex 2 500 TOTAL HEAT GENERATOR ROOM 7 920 2 The required airflow is
50. danger Don t commence any operation until you have taken all the necessary steps to ensure that you are in complete safety GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net 13 Low Voltage Control circuits utilized by the generator set are D C voltage This voltage potential is not considered dangerous but the large amount of current available over 300 amps can cause severe burns if shorted to ground 1 Disconnect the negative terminal of the battery if possible when working on the generator set Disconnect the cable end that is away from the battery 2 Do not wear jewelry watches or rings These items can short out and cause severe burns to the wearer General Safety Precautions 1 Use extreme caution if holes are drilled into the generator set Holes drilled into an electrical wire can cause fire explosion or shock hazard Be sure all mounting screws are light and are the correct length Keep tools and equipment clean and in good working condition Accidents occur when you attempt procedures without the proper tools GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 14 Safety Precautions Rotating Hazards Keep your hands clothing and tools clear of the fan and w
51. e Compare the advantages and disadvantages of using larger pipe with that of using an auxiliary coolant pump GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe TABLE 9 EQUIVALENT LENGTHS OF PIPE FITTINGS AND VALVES FEET NOMINAL DIAMETER INCHES TYPE OF FITTING 1 5 2 2 5 3 4 5 6 90 ELBOW 4 4 5 5 6 5 8 11 14 16 45 ELBOW 25 3 3 8 5 6 3 7 5 LONG SWEEP ELBOW 2 8 3 5 42 5 2 7 9 11 CLOSE RETURN BEND 13 15 18 24 31 37 TEE STRAIGHT RUN 3 5 42 5 2 7 9 11 SIDE INLET OR OUTLET 9 3 12 14 17 22 21 33 GLOBE VALVE FULLY 55 67 82 110 140 ANGLE VALVE FULLY OPEN 27 33 41 53 70 GATE VALVE FULLY OPEN 1 2 1 4 1 7 2 3 2 9 3 5 GLOBE VALVE HALF OPEN 27 33 41 53 70 100 EA 2 PRESSURE LOSS PSI PER 100 FOOT OF PIPE LENGTH 4 1712 5 AAT LEN iM HIP am 2 7 LEE LN y ean L1 LVILILULL 4 YL niil Hi 1 fal EEE ko D CELO YLLI 8 COOLANT FLOW U S GALLONS PER FIGURE 30 FRICTIONAL P
52. e coolant static head pressure can cause the coolant pump shaft seal to leak Excessive coolant friction head pressure loss will result in insufficient engine cooling Radiator hose 6 to 18 inches 152 to 457mm long complying with SAE 20R1 or equivalent standards should be used to connect coolant piping to the engine to take up generator set movement and vibration It is highly recommended that the radiator hoses be clamped with two premium grade constant torque hose clamps at each end to reduce the risk of sudden loss of engine coolant due to a hose which is under pressure slipping off Major damage can occur to an engine if it is run without coolant in the block just a few seconds A drain valve should be located at the lowest part of the system Depending on the amount of coolant in the system ball or gate valves globe valves are too restrictive are recommended to isolate the engine so that the entire system does not have to be drained before servicing the engine To obtain the net power available from the generator set add the fan load indicated on the generator set Specification Sheet to the power rating of the set and subtract the power consumed by the remote radiator fan ventilating fans coolant pumps and other accessories required for the set to run GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe
53. e weight of the set and resist the dynamic loads It is recommended that the tank be mounted such that an air space is included between the bottom of the tank and the floor underneath to reduce corrosion and permit visual inspections for leaks Mounting on a Vibration Isolating Foundation When a generator set is mounted on a foundation to reduce the transmission of vibrations to the building the weight W of the foundation should be at least 2 times the weight of the set itself to resist dynamic loading The weight of fuel in a sub base fuel tank should not be considered as contributing to the weight required of a vibration isolating foundation Figure 20 illustrates a typical vibration isolating foundation Consider the following The foundation should extend at least 6 inches 150 mm beyond the skid on all sides This determines length L and width W of the foundation e Calculate the height of the foundation necessary to obtain the required weight W by using the following formula W DxLxW Where D is the density of concrete typically 145 Ibs ft 2322 kg m The foundation should extend at least 6 inches 150 mm above the floor to make service and maintenance of the generator set easier The foundation must extend below the frost line to prevent heaving foundation should be reinforced concrete with a 28 day compressive strength of at least 2500 psi 173 kPa The total weight TW of t
54. ed such that the lowest possible fuel level is not less than 6 inches 150mm above the fuel pump inlet This will prevent air from accumulating in the fuel line while the set is in standby eliminating the period during startup when it has to be purged GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe _ Day tank fuel temperature might need to be considered in some high ambient applications when the warm fuel from the engine is returned to the day tank Call the GeneratorJoe distributor concerning inlet fuel temperature limits for specific generator set models As fuel temperature increases fuel density and lubricity decrease reducing maximum power output and lubrication of fuel handling parts such as pumps and injectors One solution might be to pipe the fuel back to the supply tank rather than to the day tank The day tank fuel transfer pump capacity and supply piping should be sized on the basis of the maximum fuel flow indicated on the generator set Specification Sheet Gaseous Fuel Figure 34 illustrates the typical gas line components in an automatic transfer dual fuel system natural gas and LPG It is also representative of single fuel systems and the natural gas or LPG fuel components used when the alternate fuel is gasoline When natural gas or LPG Is used in combination with gasoline the gas air mixer i
55. either No AWG Cu or No AWG Al or use 75 C wire either No AWG Cu or No AWG Al e Select row 1 2 3 or 4 if the circuit rating is 110 amperes or less or requires 1 AWG 42 4 mm or smaller conductors e Select row 3 or 4 if the circuit rating is greater than 110 amperes or requires 1 AWG 42 4 mm or larger conductors Comply with applicable national and local codes when installing a wiring system Use 60 C wire No AWG or use 75 C wire No AWG 60 C 140 F Use No AWG 60 C Use 60 C wire either No AWG Cu or wire No AWG Al Use 60 C wire No AWG 75 C 167 F Use AWG 75 C wire No AWG Al Use 75 C wire either AWG Cu or Use 75 C wire No AWG 90 194 F Use No 7 AWG 90 C Use 90 C wire either AWG or Use 90 C wire No wire No AWG Al AWG The wire size for 60 C 140 F wire is not required to be included in the marking If included the wire size is based on ampacities for the wire given in Table 310 16 of the National Electrical Code in ANSI NFPA 70 and on 115 of the maximum current that the circuit carries under rated conditions The National Electrical Code is a registered trademark of the National Fire Protection Association Inc Usethelarger ofthefollowing conductors the same size conductor as that used forthe temperature test or one selected using the guidelines in
56. erator set Specification Sheet The batteries may be either lead acid or nickel cadmium They must be designated for this use and may have to be approved by the authority having jurisdiction high output engine driven alternator and automatic voltage regulator are provided to recharge the batteries during operation e For emergency power systems a float type battery charger powered by the normal power source must be provided to keep the batteries fully charged during standby Codes usually specify a maximum battery charging time The following rule of thumb can be used to size battery chargers Required Battery Charging Amps 1 2 x Battery Amp Hours Charging Hours Local codes may require battery heaters to maintain a minimum battery temperature of 50 10 C if the set is subject to freezing temperatures e Standard sets include skid mounted battery racks and battery cables e Battery cable resistance must not result in a voltage drop between the battery and the starter motor of more than 1 volt for 12 volt systems or more than 2 volts for 24 volt systems See the following example calculation FIGURE 36 TYPICAL ELECTRIC STARTER MOTOR CONNECTIONS STARTER POSITIVE BATTERY SOLENOID CABLE CONNECTION NEGATIVE BATTERY CABLE CONNECTION GeneratorJoe 50 Example Calculation A generator set has a 24 VDC starting system to be powered by two 12 volt batteries connected in series Figure 36
57. fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions Fuel tanks Explosive fuel vapors can cause
58. he ground cable last again away from the battery GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Electrical Hazards High Voltage When servicing or repairing a generator set the possibility of serious or even fatal injury from electrical shock exists Extreme care must be used when working with an operating generator Lethal voltage potentials can exist on connections that are in the exciter control box Precautions When working on high voltage circuits on the generator set do not make any rapid moves If a tool drops do not grab for it People do not contact high voltage wires on purpose It normally occurs from an unplanned movement Make sure of your footing If you slip you will instinctively grab for support This can be lethal around a generator set Work on rubber mats or dry wood if possible Use tools with insulated handles that are in good condition Never hold metal tools in your hand if exposed energized conductors are within reach Treat all wires and connections as high voltage until a meter and wiring diagram show otherwise IMMEDIATE action must be initiated after a person has received an electric shock Obtain expert medical assistance if available The source of shock must be immediately removed by either shutting down the generator power or removing the victim from the source If it is not poss
59. he generator set fuel and foundation usually results in a soil bearing load SBL of less than 2000 Ibs ft2 96 kPa Although this is within the load bearing capacity of most soils always find out the allowable soil bearing load by checking the local code and the soil analysis report for the building Calculate the soil bearing load by using the following formula TW LxW SBL Where L and W are the length and width of the foundation GeneratorJoe 17 Type J or L bolts should be used to anchor the skid or vibration isolators to the foundation LTTE SPRING TYPE VIBRATION ISOLATOR ANCHORED WITH TYPE J OR L BOLTS SEE DETAIL Et Per TUM T SS 5 5 SS 52265256 2500 PS 173 REINFORCED 2 UN CONCRETE FOUNDATION 554 D ENY OAK 8 HION USES AN 2454256 2202 MET 25292909575742654 OF 27556555 35655555555 555 963561 48555555454668 5455555 2329222 255 52525252 5 5899 5255452 90525295928 200420 4202 59252922254541652802486 4546252 lt 24242424 5 6 4 555054556 fef sdaf af odes 959555255555 555 59 5 L 5 DETAIL OF TYPE J OR L BOLT ANCHORING FIGURE 20 TYPICAL VIBRATION ISOLATING FOUNDATION 18 EXHAUST SYSTEM The function of the exhaust system is to convey engine exhaust safely to the out of doors and to disperse the exhaust fumes soot and noise away from peo
60. hecking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level atthe tank ifthe generator set has a coolant recovery tank Moving Parts WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 12 DO Do perform your tasks carefully without undue haste Do provide fire extinguishers rated ABC Do provide a First Aid Kit for burns and abrasions Obtain
61. ible to shut off the generator set the wire should be cut with either an insulated instrument such as a wooden handled axe or cable cutters with heavy insulated handles or a rescuer wearing insulated gloves Whichever method is used do not look at the wire while it is being cut The ensuing flash can cause blindness Remember that insulated gloves are manufactured for protection from liquids If the victim has to be removed from live circuitry knock him off DO NOT TOUCH HIM you could receive a shock from current flowing through his body After separating the victim and power source check immediately for respiration and presence of a pulse If a pulse is present respiration can be restored by mouth to mouth resuscitation eneratorJoe Installation MOUNTING The foundation floor or roof must be able to support the weight of the generator set and its accessories such as a sub base fuel tank resist dynamic loads and not transmit objectionable noise and vibration See the generator set Specification Sheet or outline drawing for the weight of the generator set and its mounting points Vibration Isolators Figure 19 illustrates a steel spring vibration isolator of the type required for mounting the larger GENERATORJOE generator sets even those models which have rubber vibration isolators between the skid and the engine generator assembly Steel spring isolators of this type can provide up to 98 percent reduction in the force of the vibr
62. ic service to keep the unit in proper operating condition Included with the unit should be an engine operator s guide and a generator operators guide to assist a generator technician in maintaining the unit Installation of the unit should be done in compliance with the installation section of this manual Proper installation in accordance with the National Electric Code Occupational Safety and Health Administration OSHA and local safety codes must be strictly complied with Proper grounding is essential in preventing possible electrical shock and even death Remember safety begins with the owner operator of the unit Make sure to keep fingers hair jewelry and clothing away from the revolving parts of the generator set such as belts fan blade and generator rotor fan Operation of the unit should be first done by GENERATORJOE authorized start up personnel so that they make sure the unit was properly installed and is functioning properly with the load system being applied to the unit The start up personnel will instruct the owner on basic procedures and will answer any questions the owner may have on general operation and maintenance Before performing routine maintenance disconnect the unit from the load and disable the control system as discussed in the maintenance section Disabling the System Proper maintenance is the primary method of assuring the unit will operate when it is needed Review each of the sections before proceeding with inst
63. illustrate typical applications Consider the following It is recommended that the radiator and fan be sized on the basis of a maximum radiator top tank temperature of 200 F 93 C and a 115 percent cooling capacity to allow for fouling The generator set Specification Sheet indicates the Heat Rejected To Cool ant and Coolant Flow Rate necessary for radiator sizing according to the radiator manufacturer s instructions The capacity of the radiator top tank or auxiliary tank must be equivalent to at least 15 percent of the total volume of coolant in the system to provide a coolant drawdown capacity 10 percent and space for thermal expansion 5 percent Drawdown capacity is the volume of coolant that can be lost by slow undetected leaks and the normal relieving of the pressure cap before air is drawn into the coolant pump Space for thermal expansion is created by the fill neck when a cold system is being filled See Figure27 To reduce radiator fin fouling radiators having a more open fin spacing nine fins or less per inch should be considered for dirty environments Coolant friction head external to the engine pressure loss due to pipe fitting and radiator friction and coolant static head height of liquid column measured from crankshaft centerline must not exceed the maximum allowable values on the generator set Specification Sheet See the example calculation below for a method of calculating coolant friction head Excessiv
64. ily then you may apply the load if you wish in your normal prescribed method Some units may have a manual means of applying the load and some may have an automatic transfer switch which may have a with or without load test Selector switch The start up technician will have set the automatic exercise Clock if the unit was purchased with one This feature starts the generator set and applies the load once a month or sometimes once a week depending on the type of transfer switch ordered If the transfer switch has the test with load feature witness of this test should be done periodically to verify the exercise period is occurring and keeping the unit battery charged up Some units may also have a battery charger hooked up which is powered by the utility system to assist in maintaining the battery in a properly charged condition A battery charger is recommended in automatic standby operation of a GeneratorJoe generator set Always replace the control switch back in the automatic position when completing an inspection of the unit so that the automatic transfer switch can start the unit if a utility power failure occurs When an inspection of the unit detects any unusual meter readings noises or vibrations notify an authorized GeneratorJoe Dealer to correct the problem For further information regarding the Generator Set Control Panel refer to the Generator Set Controller Instruction Manual GeneratorJoe Maintenance and Service GENERAL A wel
65. in the piping system to the connection at the radiator top tank or auxiliary tank No other piping should be connected to it This arrangement allows the system to be filled from bottom up without trapping air and giving a false indication that the system is full With proper vent and fill line connections it should be possible to fill the system at a rate of at least 5 gpm 19 L Min approximately the flow rate of a garden hose GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe FROM ENGINE VENT LINE 5 OF COOLANT FLOW TOP TANK VOLUME MUST EQUAL 10 OF TOTAL SYSTEM VOLUME DRAWDOWN CAPACITY PLUS 5 FOR THERMAL EXPANSION HOT COOLANT FROM DEAERATED FILUMAKEUP COOLANT FILL NECK WITH VENT HOLE ENGINE TO RADIATOR FROM FROM TOP TANK ABOVE BAFFLE TO CREATE THERMAL BELOW BAFFLE PLATE PLATE TO LOWEST POINT IN SYSTEM EXPANSION SPACE FIGURE 27 DEAERATION TYPE OF RADIATOR TOP TANK Remote Radiator with Auxiliary Coolant Pump A remote radiator with an auxiliary coolant pump Figure 28 can be used if coolant friction exceeds the allowable value on the generator set Specification Sheet In addition to the considerations under Remote Radiators consider the following e auxiliary pump and motor must be sized for the coolant flow indicated on the generator set Specification Sheet and develop enough head
66. ining the airflow required to meet room air temperature rise specifications if any Because the radiator fan will cause a slight negative pressure in the generator room it is highly recommended that combustion equipment such as the building heating boilers not be located in the same room as the generator set If this is unavoidable it will be necessary to determine whether there will be detrimental effects such as back draft and to provide means extra large room inlet openings and or ducts pressurizing fans etc to reduce the negative pressure to acceptable levels ncolder climates automatic dampers should be used to close off the inlet and outlet air openings to keep the generator room warm when the set is not running And a thermostatic damper should be used to re circulate a portion of the radiator discharge air to reduce the volume of cold air that is pulled through the room when the set is running The inlet and outlet dampers must fully open when the set starts The re circulating damper should close fully at 60 F 16 C Other than re circulating radiator discharge air into the generator room in colder climates all ventilating air must be discharged directly to the out of doors It must not be used to heat any space other than the generator room flexible duct connector must be provided at the radiator to take up generator set movement and vibration and prevent transmission of noise e Ventilating air inlet and dis
67. ith tools or jewelry while making adjustments or repairs Remove wristwatch rings and jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into utility electrical system can cause serious injry or death to utility personnel working on power lines Installing accessories to the transformer assembly Hazardous voltage can cause severe injury or death To prevent electrical shock disconnect the harness plug before installing accessories that will be connectedto the transformer assembly primary terminals on microprocessor logic models Terminals are at line voltage Making line or auxiliary connections Hazardous voltage can cause severe injury or death To prevent electrical shock deenergize the normal power source before making any line or auxiliary connections Servicing the transfer switch Hazardous voltage can cause severeinjury or death Deenergize all power sources before servicing Open the main circuit breakers of all transfer switch power sources an
68. ize of the leads may be smaller than required for field installed conductors because generator leads have type CCXL insulation rated 125 C If the generator set is factory equipped with a main line circuit breaker the ampacity of the field installed AC phase conductors connected to the load terminals of the circuit breaker should be equal to or greater than the circuit breaker rating See Schematic c in Figure 39 FIGURE 39 FEEDER AMPACITY a No Main Line Circuit Breaker 116 OF GENERATOR FLA b Remote Main Line Circuit Breaker 115 OF EQUAL GREATER GENERATOR THAN REMOTE BREAKER FLA Generator Mounted Main Line Circuit Breaker can at _ iu MN T EQUAL GREATER V BREAKER THAM GENERATOR RATING THE AUTOMATIC TRANSFER SWITCHES GeneratorJoe 53 The ampacity of the neutral conductor is generally permitted to be equal to or greater than the calculated maximum single phase unbalance of the load Where a significant portion of the load is non linear the neutral should be full size The generator neutral supplied by GeneratorJoe is equal in ampacity to the phase conductors Flexible metal conduit and stranded conductors must be used for connections to the generator set to take up generator set movement and vibration The flexible conduit should be at least 18 inches 460 mm long Medium voltage cable must be installed and terminated exac
69. l depend on the minimum cranking time required All of the starters available from GeneratorJoe have a maximum pressure rating of 150 psig 1035 kPa e Air tanks receivers should be fitted with a drain valve of the screw out tapered seat type other types unreliable and a common source of air leaks Moisture can damage starter components valves and accessories in the system should be designed for diesel air starting service e Pipe fittings should be of the dry seal type and should be made up with thread sealant Teflon tape is not recommended as it does not prevent thread loosening and can be a source of debris that can clog valves ORAIN LINE FIGURE 38 TYPICAL PIPING ARRANGEMENT FOR AN AIR STARTER 32 ELECTRICAL CONNECTIONS General Installation of electrical wiring should follow the requirements of the applicable electrical code and be done by qualified persons AC Power Conductors If the generator set is not factory supplied with a main line circuit breaker the ampacity of the field installed AC phase conductors from the generator output terminals to the first over current device should be at least equal to 115 percent of the generator full load current See Table 16 and Schematics a and b in Figure 39 The length of run for generator tap conductors to the first overcurrent device should be kept as short as possible generally not more than 25 feet If the generator is supplied with leads the s
70. l planned program of preventive maintenance and service should be integral to the design of an on site power system Failure of a standby generator set to start and run could lead to loss of life personal injury property damage and loss of business income Failure to start and run due to low battery charge because of careless maintenance is the most common type of failure A comprehensive program carried out on a scheduled basis by qualified persons can prevent such failures and their possible consequences The maintenance and service programs most generator set distributors offer on a contract basis should be considered Typically they include performance of scheduled maintenance repairs parts replacement and service documentation SCHEDULED MAINTENANCE The maintenance schedule for prime power sets should be on the basis of running time as published by the manufacturer Since standby sets run infrequently the maintenance schedule is usually in terms of daily weekly monthly semi annual and annual tasks See the manufacturer s instructions for details but scheduled maintenance should include at least Daily e Checking for oil coolant and fuel leaks e Checking operation of the engine coolant heater s If the block is not warm the heaters are not working and the engine might not start e Checking to see that the switchgear is in the AUTOMATIC position Weekly e Checking engine oil and coolant levels e Checking the battery charging
71. m3 hr 378 568 757 946 1514 2461 200 cfh 250 300 400 600 1000 2000 6 m3 hr 946 1136 1514 2271 3785 7571 300 400 600 700 1100 1800 3600 9 m hr 1514 2271 2650 4164 6814 13 627 400 600 900 1200 1700 2700 4500 11 m hr 2271 3407 4542 6435 10 221 17 034 500 cfh 900 1300 1600 2500 3600 7500 14 m hr 3407 4921 6057 9464 13 627 28 931 600 1100 1600 2000 3000 5000 10 000 17 m3 nr 4164 6057 7571 11 356 18 927 37 854 700 1500 2000 2500 4000 6000 13 000 20 m hr 5678 7571 9464 20 820 22 712 49 210 Example Gas Pipe Sizing Calculations An application calls for two natural gas generator sets The sets could be run concurrently The full load fuel consumption indicated on the generator set Specification Sheet for the model selected is 890 cfh cubic feet per hour The two sets will be supplied by a service pressure regulator adjusted to maintain 14 inches 356 mm WC water column The service pressure regulator wilt not serve any other load Figure 35 illustrates the gas piping arrangement FIGURE 35 GAS PIPING LAYOUT FOR A TWO GENERATOR INSTALLATION GAS PRESSURE 10 10 REGULATOR GENERATOR SETS GeneratorJoe Determine minimum pipe sizes as follows 1 Add up the length of pipe to the generator set farthest from the source which is generator set B Total length of pipe for Set B
72. mperature above room temperature 1 14mm per meter per 100 C rise It is recommended that flexible corrugated stainless steel tubing be used to take up expansion in long straight runs of pipe Horizontal runs of exhaust piping should slope downwards away from the engine to the out of doors or to a condensate trap A condensate drain trap and plug should be provided where piping turns to rise vertically The exhaust system must terminate out of doors at a location where engine exhaust will disperse away from buildings and building air intakes and not blacken walls and windows with soot It is highly recommended that the exhaust system be carried up as high as practical on the downwind side of buildings and that it discharge straight up to maximize dispersal Some codes specify that the exhaust outlet terminate at least 10 feet from the Property line 3 feet from an exterior wall or roof 10 feet from openings into the building and at least 10 feet above the adjoining grade A rain cap should be provided if the exhaust outlet points up A generator set should not be connected to an exhaust system serving other equipment including other generator sets Soot corrosive condensate and high exhaust gas temperatures can damage idle equipment served by a common exhaust system GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Generator
73. n Ib 32 1 8 5 1 45 40 5 32 11 4 100 48 3 16 13 8 120 56 7 32 17 0 150 6 4 1 4 22 6 200 79 5 16 311 275 9 5 3 8 42 4 375 12 7 1 2 56 5 500 143 9 16 67 8 600 GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net Note For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Tightening Torque for Pressure Wire Connectors with Internal Drive Socket Head Screws GeneratorJoe Grounding System Grounding As shipped the neutral terminal of a GeneratorJoe generator is not grounded If the generator is a separately derived power source i e 4 pole transfer switch then the neutral will have to be connected to a grounding electrode system by the installing electrician If the generator neutral Interconnects with a service supplied grounded neutral typically at the neutral block of a 3 pole transfer switch then the generator neutral should not be grounded at the generator The electrical code may require a sign to be placed at the service supply indicating that the generator neutral is grounded at that location Equipment Grounding A grounding terminal is provided on the skid of the genera
74. nal load connections are made to serve as benchmarks for the annual tests These tests are mandatory for medium voltage generator sets ANSI TEEE Standard 43 Recommended Practice for Testing Insulation Resistance of Rotating Machinery should be referenced GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net GeneratorJoe 63 TROUBLESHOOTING What are some of the most often found reasons for a failure of a generator set to start Below is a list of some of the areas overlooked when maintaining a generator set 1 Battery Cables A battery cable often looks as if it is in good condition but in fact may be the cause of a non start of the generator set Corrosion often starts on the inside of the cable insulation and is not visible from the outside without testing the resistance value from one end to the other Battery cable checks are listed in most operator guides and in order to keep the units running properly the cables must be kept clean and free from corrosion 2 Bad Fuel Fuel systems are the second highest cause for failure to start or fail during an outage without being able to supply power for the full period of the outage The major factor is usually algae or water in the fuel tank which develops from not exchanging the fuel regularly or not adding algae or water preventive additives to prevent this contamination There are
75. neratorjoe NET Web www generatorjoe net GeneratorJoe 39 THREE PHASE LOAD AS PERCENTAGE OF THREE PHASE RATING SINGLE PHASE LOAD AS PERCENTAGE OF THREE PHASE kVA RATING BALANCED SINGLE FIGURE 41 ALLOWA PHASE LOAD oe FR 60 EA b OPERATION WARNING BE SURE PROPER START UP HAS BEEN PERFORMED ON YOUR GENERATORJOE GENERATOR SET BEFORE ATTEMPTING TO OPERATE THE UNIT ON YOUR OWN If proper start up has taken place then the following events have already occurred 1 The start up technician has reviewed the installation and has tested the unit by applying the load and making sure all generator installation requirements have been met 2 The start up technician has reviewed the overall requirements for the SAFE operation of the unit with the personnel assigned to the daily inspection and operation of the unit 3 The warranty forms and documentation are being processed and the unit is ready for operation The following should occur before any witnessed start of the unit 1 Check fluid levels such as radiator water level engine oil level fuel level and battery fluid level Correct any that may appear either too high or too low Refer to the engine manufacturers guide for assistance in determining these proper levels 2 Inspect the unit for any noticeable loose connections or leaks Refer to the applicable manual for remedy of the problem or call GeneratorJoe service department f
76. ning sediment from fuel tanks checking flexible fuel hoses for cuts and abrasions and checking the governor linkage 62 Checking electrical safety controls and alarms Cleaning up accumulations of grease oil and dirt on the set Checking power distribution wiring connections circuit breakers and transfer switches Simulating a utility power outage This should test the ability of the set to start and assume rated load and check operation of the automatic transfer switches related switchgear and controls and all other components in the standby power system Annually Checking the fan hub pulleys and water pump Changing the day tank breather Tightening the exhaust manifold and turbocharger capscrews Tightening the set mounting hardware Cleaning the generator power output and control boxes checking for and tightening all loose wiring connectors measuring and recording generator winding Insulation resistances checking operation of the generator heater strips and greasing bearings Checking operation of the main generator circuit breaker if used by manually operating it and testing the trip unit according to the manufacturer s instructions Running the set for at least three hours with one hour at near rated load if the set is normally exercised at no load or carries only light loads Generator Insulation tests should be conducted annually throughout the life of a generator set The initial tests should be done before fi
77. or assistance The unit has a manual position that will start the unit as soon as the switch is placed in the manual position There will be a slight time delay through the control module and then the starter will engage and crank the engine over If everything is in proper running condition the engine will accelerate to rated no load speed and run until the switch is returned to the OFF position or the AUTO position The unit will not start in the AUTO position unless the automatic transfer switch is requiring it to start If the unit starts when the control switch is placed in the AUTO position then it means that the utility is no longer supplying the transfer switch This is an unusual occurrence and therefore will not likely happen on testing the unit The unit once running will operate at rated speed which is generally 1800 RPM plus the droop setting if the unit load is not applied Initial readings on oil pressure and water temperature should be monitored to make sure they appear to be working properly Also monitor the frequency and voltage on the AC meters to verify that the generator is producing voltage at the proper level If any of the observations appear abnormal according to the respective operator guides then make note of the apparent discrepancy and turn the unit to the OFF position Tag the unit as out of service and call GeneratorJoe service department for assistance If the unit is operating satisfactor
78. orJoe warrants to original purchaser for the period set forth below that goods manufactured or supplied by it will be free from defects in workmanship and material provided such goods are installed operated and maintained in accordance with GeneratorJoe s instructions and further provided that installation inspection and initial start up on commercial Industrial generator sets or installations are conducted by a GeneratorJoe s authorized distributor or its designated service representative Warranty Periods a b or Standby generators must be permanently installed properly enclosed and ventilated or mobile application and used as back up to the normal power source The warranty period is 60 months from the date of installation by the first owner user or 60 months after date of shipment by GeneratorJoe whichever is shorter or 5000 hours of operation limited to a maximum of 1000 hours per year for 5 years whichever is shorter Continuous or Prime Duty Continuous or prime power service describes operation in a permanent or mobile application where no other source of power is generally available Rental sets and specific products for irrigation and refrigeration meet this criteria Cogeneration and peak shaving installations are considered prime power The warranty period is 12 months from date of start up by the first owner user or 18 months after date of shipment by GeneratorJoe or 3000 hours of operation To be covered by
79. ple and buildings See Figure 21 Consider the following also review Location and Noise under Application e Flexible corrugated stainless steel exhaust tubing at least 24 inches 610 mm long must be connected to engine exhaust outlet s to take up thermal expansion and generator set movement and vibration whenever the set is mounted on steel spring isolators of the type shown in Figure 19 Smaller sets that are bolted directly to the floor must be connected by corrugated stainless steel exhaust tubing at least 18 inches 457 mm long Flexible tubing must not be used to form bends or to compensate for misaligned piping To reduce corrosion due to condensate muffler should be installed as close as practical to the engine so that it heats up quickly e Mufflers and piping must be supported by non combustible hangers or supports not by the engine exhaust outlet Weight on the engine exhaust outlet can cause damage to the engine exhaust manifold or reduce the life of a turbocharger e Schedule 40 black iron pipe is recommended for exhaust piping PREVAILING WINDS gt MUFFLER SUPPORTED APPROVED THIMBLE VERTICAL INDEPENDENTLY OF THE ENGINE TO PROTECT DISCHARGE WITH amp BY NON COMBUSTIBLE STRAPS COMBUSTIBLE WALL RAIN CAP imm T TU n an 443 um t m m HHH ZATRT 4 i E Ud 535555 655555555559995 EL d LHA HAHAHHA CONDENSATE DRAIN PIPE BEND FIGURE
80. plosive fumes Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke orpermitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove wristwatch rings and other jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case Ifbattery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may resultin hazardou
81. pressure to overcome the excess coolant friction head calculated by the method shown in the example above One foot of pump head pump manufacturer s data is equivalent to 0 43 PSI of coolant friction head pressure loss or one foot of coolant static head height of liquid column lt A bypass gate valve globe valves too restrictive must be plumbed in parallel with the auxiliary pump for the following reasons e allow adjustment of the head developed by the auxiliary pump the valve is adjusted to a partially open position to recirculate some of the flow back through the pump e allow operation of the generator set under partial load if the auxiliary pump fails the valve is adjusted to a fully open position Coolant pressure at the inlet to the engine coolant pump measured while the engine is running at rated speed must not exceed the maximum allowable static head shown on the generator set Specification Sheet Also for deaeration type cooling systems 150 kW and larger generator sets auxiliary pump head must not force coolant through the make up line into the radiator top tank or auxiliary tank In either case the pump bypass valve must be adjusted to reduce pump head to an acceptable level obtain the net power available from the generator set add the fan load Indicated on the generator set Specification Sheet to the power rating of the set and subtract the power consumed by the remote radiator fan
82. r or liquid to liquid heat exchanger form a closed pressurized cooling system The most common generator set configuration has a mounted radiator and engine driven fan to cool the coolant and ventilate the generator room Alternative methods for cooling the coolant include a mounted liquid to liquid heat exchanger a remote radiator or a remote liquid to liquid heat exchanger GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net 25 Factory Mounted Radiator A generator set with a factory mounted radiator Figure 24 is an integral cooling and ventilating system This is the recommended configuration involving the least amount of auxiliary equipment piping control wiring and coolant A primary consideration for installations of this type is the necessity of moving large quantities of air through the generator room See Ventilation in this section FIGURE 24 FACTORY MOUNTED RADIATOR COOLING PREVAILING WINDS 39 ENGINE DRIVEN FAN _ AIR INLET 4 7 o e 55 55555 5555555 0 gt 5555 5 NN N x N m a a ENGINE DRIVEN COOLANT PUMP FLEXIBLE DUCT CONNECTOR WIND NOISE BARRIER
83. rranty gives the user specific rights and the user may also have other rights which vary from state to state Check component manufacturer s warranties to determine if their coverage exceeds GeneratorJoe s warranty coverage revised 1 01 2011
84. s mounted on the air horn of the gasoline carburetor Not shown is the LPG vaporizer supplied with GeneratorJoe generator sets equipped for liquid withdrawal of LPG engine mounted on outdoor sets only The service pressure regulator s dry gas filter s and manual shutoff valve s are typically provided by the installer Natural gas generator sets are tested and rated using natural gas having a heating value of approximately 1 000 Btu ft 3724 MJ m With proper fuel mixture adjustments see the generator set Service Manual fuel gases of lower heating value can be used with good results but with lass maximum power output Depending on the fuel deratings will be necessary The following should be considered when installing a natural gas and or LPG fuel system Gaseous fuel supply system design materials components fabrication assembly installation testing inspection operation and maintenance must comply with the applicable codes See NFPA Standards No 30 No 37 No 54 and No 58 e The layout and sizing of the gas supply piping must be adequate for supplying the volume of gas required at full load as indicated on the generator set Specification Sheet while maintaining at least the minimum required supply pressure typically 10 Inches 254 mm WC water column See the example pipe sizing calculation below and associated pipe sizing tables Tables 14 and 15 Final determination of pipe sizes must however be based upon the method
85. s spattering of battery acid Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove wristwatch rings and other jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal ofthe starter solenoid Do not test the battery condition by shorting the terminals together Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Engine Backfire Flash Fire WARNING Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the car
86. t transfer switch and related equipment electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Servicing the day tank Hazardous voltage can cause severe injury or death Service the day tank electrical control module ECM as prescribed in the equipment manual Disconnectthe power to the day tank before servicing Press the day tank ECM OFF pushbutton to disconnect the power Notice that line voltage is still present within the
87. t the battery charger enclosuretothe ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Servicing the day tank Hazardous voltage can cause severe injury or death Service the day tank electrical control module ECM as prescribed in the equipment manual Disconnectthe powerto the day tank before servicing Press the day tank ECM OFF pushbutton to disconnect the power Notice that line voltage is still present within the ECM when the POWER ON lightislit Ensure that the generator set and day tank are electrically grounded Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections w
88. test substances which allow testing of the tank to see if water is present and this should be performed quarterly 3 Corrosion Electrical connections are subject to corrosion even though GeneratorJoe units are treated at the factory to help prevent corrosion from occurring Check terminal connections periodically 4 Operator adjustments Often times there is a problem with personnel adjusting units without checking the proper method in the operator guides which lead to an unsuccessful start attempt and damage to property or worse injury or death to personnel DO NOT adjust the generator set controls without the proper training in performance of the work 5 Rodent pest contamination Insulation on electrical wires is often a treat for rodents which can lead to a failure to start of the generator set Another problem is rodent or pest nesting which can lead to plugging of the air cleaner or radiator cap left off Inspect the unit carefully for rodent or pest contamination 6 Improperly maintained coolant heater The coolant heater is an integral part of an automatic starting system and is often overlooked when checking out a unit Generally this occurs because the unit is turned off in the summer time and is merely left off after winter comes The diesel unit will not start properly when the coolant heater is turned off and the air temperature falls below 80 degrees Fahrenheit 7 Dead battery This is the most unfortunate reason for a failure
89. tly as recommended by the cable manufacturer by persons who have learned the procedures through training and practice under close supervision TABLE 16 THREE PHASE AC GENERATOR AMPERAGE AT 80 POWER FACTOR KW 208V 220V 240V 380V 440V 480V 600 2400V 3300V 4160V 20 25 69 66 60 38 33 30 24 35 44 122 115 105 67 57 53 42 40 50 139 131 120 76 66 60 48 45 56 156 148 135 86 74 68 54 50 63 174 164 151 95 82 75 60 65 81 226 213 196 124 107 98 78 70 88 243 230 211 133 115 105 84 80 100 278 263 241 152 131 120 96 100 125 347 328 301 190 164 151 120 125 156 434 411 376 238 205 188 151 150 188 521 493 452 285 246 226 181 175 219 608 575 527 333 287 263 211 200 250 695 657 602 380 328 301 241 230 288 799 755 692 437 378 346 277 250 313 868 821 753 475 411 376 301 5 275 344 955 903 828 523 452 414 331 300 375 1042 985 903 570 493 452 361 350 438 1216 1150 1054 666 575 527 421 400 400 1390 1314 1204 761 657 602 482 450 563 1563 1478 1355 856 739 677 542 500 625 1737 164
90. tor set If a set mounted circuit breaker is provided a grounding terminal may be provided inside the circuit breaker enclosure The electrical code may require a grounding conductor so that the section of flexible conduit required because of vibration is not relied on as a means for equipment grounding Control Wiring AC and DC control wiring to the transfer switch and remote annunciators must be run in separate conduit from the power cables Stranded conductors and a section of flexible conduit must be used for connections at the set Accessory Branch Circuits Branch circuits must be provided for all accessory equipment necessary for operation of the generator set These circuits must be fed either from the load terminals of an automatic transfer switch or from the generator terminals Examples of accessories include the fuel transfer pump coolant pumps for remote radiators and motorized louvers for ventilation Branch circuits fed from the normal power panel board must be provided for the battery charger and coolant heaters if used See Figure 40 GeneratorJoe 4723 Muirfield Court Santa Rosa CA 95405 Phone 707 539 9003 Fax 707 539 5212 Email sales generatorjoe NET Web www generatorjoe net eneratorJoe 57 NORMAL POWER GENERATOR HEATER NORMAL AC POWER TO COOLANT HEATER NORMAL AC POWER TO LUBE O HEATER BETES 1 THESE LOAI CAN BE PCRVEIRED DIRECTLY OFF THE GENERIC AITH APPROPRIATE CAER
91. ttings and flexible tube sections by using Table 8 TABLE 8 EQUIVALENT LENGTHS OF PIPE FITTINGS FEET NOMINAL DIAMETER INCHES 2 125 3 35 4 5 6 8 10 12 TYPE OF FITTING STANDARD ELBOW 53 64 81 9 6 11 14 16 21 26 32 MEDIUM RADIUS ELBOW 46 5 4 6 8 8 9 12 14 18 22 26 LONG RADIUS ELBOW 3 9 42 3 2 6 7 9 11 14 17 20 45 ELBOW 1 5 2 23 26 3 4 4 5 6 8 9 STANDARD TEE 13 14 17 19 22 24 34 44 56 67 18 INCH FLEXIBLE TUBE 3 3 3 3 3 3 3 3 24 INCH FLEXIBLE TUBE 4 4 4 4 4 4 4 4 4 4 3 Find the backpressure at the given exhaust flow per unit length of pipe for each nominal pipe diameter used in the system In this example 5 inch and 6 inch nominal pipe is used Following the dashed lines in Figure 23 5 inch pipe causes a backpressure of approximately 0 35 inches WC Water Column and 6 inch pipe approximately 0 145 inches WC 4 Add the back pressures for all elements of the example as follows 21 5 One 5 Inch Flexible Tube O 35 x 4 1 4 20 Feet of 6 Inch Pipe 0 145 x 20 Tt eerte e te vase dues 29 One 6 Inch Long Radius Elbow 0 145 x 11 Imm nee 1 6 TOTAL EXHAUST BACK PRESSURE Inches WC ccsscescccsscceccccessccesc

STANDBY GENERATOR SET

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